When 0.01mm details are accurately captured: this production line is rewriting the rules of cable quality control

When “hairline defects” become the inspection standard

In the golden 3 seconds of cable extrusion molding, temperature fluctuations of 0.5 ℃, mold gap 0.01mm deviation, may leave imperceptible hidden defects on the surface of the cable. Those bubbles hidden in the depths of the dent, embedded in the grain of the coke particles, and even high-speed friction generated by the micron-level scratches, is flowing in the production line at a speed of 400 meters per minute. Traditional 2D inspection can only “look at the skin”, face the surface of the water marks on strike, encounter reflections on the “blind”, and sharp eye 3D inspection equipment equipped with industrial-grade laser scanning system, as to the production line with a CT scanner, not only to capture the XYZ three-dimensional coordinates, but also penetrate the surface of the interference, so that the depth of the change in the 0.01mm in the 3D modeling of nothing to hide.

Let the algorithm become a 24-hour on-line “special quality inspector”.

In the lab of a leading cable manufacturer in Jiangsu, engineers are importing a new batch of defective samples -- this time carbonized spots from extreme environments. The CNN deep learning model built into the device automatically updates its parameters, and the “smart brain” that has already learned 100,000+ defect samples can automatically adjust the detection threshold according to the cable material (cross-linked polyethylene/polyvinyl chloride), production speed, and ambient temperature and humidity. While traditional manual inspection is still frequently calibrating parameters for different batches of products, the adaptive algorithm of Sharpvision has already realized accurate inspection for “thousands of people”: when inspecting polyethylene sheaths, the system will strengthen the identification of pits below 0.05mm; in the face of high-voltage crosslinked cables, the detection accuracy of protruding particles will be automatically increased to the 0.01mm level.

Production line “cost reduction magic” is happening

Zhejiang a cable enterprise workshop director Lao Li calculated a fine account: in the past, two people to keep an eye on a production line, but also sampling 50 meters per shift to do destructive testing, and now a person to easily monitor the two lines. When the equipment in 0.03 seconds to complete the image acquisition, millisecond algorithms synchronized to complete the defect location, the system has automatically generated containing defect coordinates, depth data, resulting in the analysis of the time period of the report. Last week's sudden mold scratches in the production line, it is through the historical data comparison, to help the process department lock the mold maintenance cycle optimization node. Three months down the line, the workshop defective rate from 1.2% to 0.15%, the backlog of products to be inspected in the quality inspection area is less, and the waste of raw materials is directly cut in half.

Stabilizing Outputs in Complex Environments

In the hot and humid workshop of a coastal cable factory in Guangdong, the salt spray brought by the sea breeze is testing the “anti-interference ability” of the testing equipment. The unique multi-spectral light source system of Sharp Dagger Vision plays a powerful role at this moment: the special wavelength light source penetrates the water mist and hits the light accurately, and the professional optical structure refuses to be interfered by daylight reflection, so that even if the cable surface is attached to the lubricant or coolant, the 3D depth data is still output stably. Compared to the old equipment that required frequent calibration because of changes in ambient light, this system has now achieved a defect recognition rate of 99.98% in 24-hour continuous operation.

When more and more cable companies are beginning to realize that the 0.01mm difference in detection accuracy, behind the leap in yield, customer complaints, and even access to high-end markets, the sharp knife view is using technology to redefine the quality inspection standards. From 50mm low-voltage cables to 150mm ultra-high voltage cables, from smooth rubber sheaths to armor layers with complex patterns, this system always guards the safety bottom line of every meter of cables with the persistence of “not letting go of a hidden danger”.

Now, does your production line also need such a tireless and precise “intelligent quality inspector”? Click to make an appointment for on-site inspection, and let us use 3D vision technology to build a micron-level protective wall for your product quality. After all, in the battlefield of cable safety, the details, are never trivial.